Powdered material (p) containing poly(arylene sulfide) (pas) polymer and its use for additive manufacturing

Abstract

The present invention relates to a powdered material (M) containing at least one poly(arylene sulfide) (PAS) polymer, comprising recurring units p, q and r according of formula (I), (II) and (III): wherein n p , n q and n r are respectively the mole % of each recurring units p, q and r; recurring units p, q and r are arranged in blocks, in alternation or randomly; 1%≤(n q +n r )/(n p +n q +n r )≤12%; nq is ≥0% and nr is ≥0%; j is zero or an integer varying between 1 and 4; R 1 is selected from the group consisting of halogen atoms, C 1 -C 12 alkyl groups, C 7 -C 24 alkylaryl groups, C 7 -C 24 aralkyl groups, C 6 -C 24 arylene groups, C 1 -C 12 alkoxy groups, and C 6 -C 18 aryloxy groups.

1 . A powdered material (M) for additive manufacturing, having a d 50 -value ranging between 10 and 100 μm, as measured by laser scattering in isopropanol, comprising:
 one polymeric component (P) comprising at least one poly(arylene sulfide) (PAS) polymer, comprising recurring units p, q and r according of formula (I), (II) and (III): 
 
       
         
           
           
               
               
           
         
         wherein 
         n p , n q  and n r  are respectively the mole % of each recurring units p, q and r; recurring units p, q and r are arranged in blocks, in alternation or randomly; 
         1%≤(n q +n r )/(n p +n q +n r )≤12%; n q  is ≥0% and n r  is ≥0%; 
         j is zero or an integer varying between 1 and 4; 
         R 1  is selected from the group consisting of halogen atoms, C 1 -C 12  alkyl groups, C 7 -C 24  alkylaryl groups, C 7 -C 24  aralkyl groups, C 6 -C 24  arylene groups, C 1 -C 12  alkoxy groups, and C 6 -C 18  aryloxy groups, 
         optionally one or several flow agent(s) (F), 
         optionally one or several additive(s) (A) selected from the group consisting of lubricants, heat stabilizers, light stabilizers, antioxidants, pigments, processing aids, dyes, fillers, nanofillers or electromagnetic absorbers and flame retardants. 
       
     
     
         2 . The powdered material (M) of  claim 1 , wherein the PAS is such that n p +n q +n r ≥50%. 
     
     
         3 . The powdered material (M) of  claim 1 , wherein the PAS is such that it consists or consists essentially of recurring units p, and recurring units q and/or r. 
     
     
         4 . The powdered material (M) of any one of  claim 1 , wherein j is zero in formula (I). 
     
     
         5 . The powdered material (M) of  claim 1 , wherein the PAS has a heat of fusion of more than 20 J/g, determined on the 2 nd  heat scan in differential scanning calorimeter (DSC) according to ASTM D3418, using heating and cooling rates of 20° C./min. 
     
     
         6 . The powdered material (M) of  claim 1 , wherein the PAS has a melting point of at most 280° C., and/or of at least 245° C., when determined on the 2 nd  heat scan in differential scanning calorimeter (DSC) according to ASTM D3418, using heating and cooling rates of 20° C./min. 
     
     
         7 . The powdered material (M) of  claim 1 , wherein the flow agent (F) is an inorganic pigment selected from the group consisting of silicas, aluminas and titanium oxide. 
     
     
         8 . The powdered material (M) of  claim 1 , wherein the flow agent (F) is fumed silica. 
     
     
         9 . The powdered material (M) of  claim 1 , wherein the material (M) has a d 50 -value ranging between 15 and 80 μm, as measured by laser scattering in isopropanol. 
     
     
         10 . A process for manufacturing a three-dimensional (3D) article, part or composite material, comprising:
 a) depositing successive layers of a powdered material (M) of  claim 1 , and   b) printing layers prior to deposition of the subsequent layer.   
     
     
         11 . The process of  claim 10 , wherein step b) comprises selective sintering by means of an electromagnetic radiation of the powder. 
     
     
         12 . A three-dimensional (3D) article, part or composite material obtainable by additive manufacturing from the powdered material (M) of  claim 1 , said additive manufacturing being selective laser sintering (SLS), composite-based additive manufacturing technology (“CBAM”) or multi jet fusion (MJF). 
     
     
         13 . A method for the manufacture of a three-dimensional (3D) object from the powdered material (M) of  claim 1 , using additive manufacturing, wherein the additive manufacturing is selective laser sintering (SLS), composite-based additive manufacturing technology (“CBAM”) or multi jet fusion (MJF). 
     
     
         14 . A method for the manufacture of a powdered material (M), for additive manufacturing, from a polymeric component (P) comprising at least one poly(arylene sulfide) (PAS) polymer, comprising recurring units p, q and r according of formula (I), (II) and (III): 
       
         
           
           
               
               
           
         
         wherein 
         n p , n q  and n r  are respectively the mole % of each recurring units p, q and r; recurring units p, q and r are arranged in blocks, in alternation or randomly; 
         1%≤(n q +n r )/(n p +n q +n r )≤12%; n q  is ≥0% and n r  is ≥0%; 
         j is zero or an integer varying between 1 and 4; 
         R 1  is selected from the group consisting of halogen atoms, C 1 -C 12  alkyl groups, C 7 -C 24  alkylaryl groups, C 7 -C 24  aralkyl groups, C 6 -C 24  arylene groups, C 1 -C 12  alkoxy groups, and C 6 -C 18  aryloxy groups, 
         optionally in combination with one or several flow agent(s) (F) and/or one or several additives (A), 
         wherein the additive manufacturing is selective laser sintering (SLS), composite-based additive manufacturing technology (“CBAM”) or multi jet fusion (MJF). 
       
     
     
         15 . (canceled) 
     
     
         16 . The powdered material (M) of  claim 1 , wherein the melting point is of at most 278° C. and/or of at least 248° C. when determined on the 2 nd  heat scan in differential scanning calorimeter (DSC) according to ASTM D3418, using heating and cooling rates of 20° C./min. 
     
     
         17 . The powdered material (M) of  claim 1 , wherein the melting point is of at most 275° C. and/or of at least 250° C. when determined on the 2 nd  heat scan in differential scanning calorimeter (DSC) according to ASTM D3418, using heating and cooling rates of 20° C./min.